Method for manufacturing a gill faller of a constant thickness faller body type

ABSTRACT

A method for manufacturing a gill faller of a constant thickness faller body type wherein a faller body is formed by an application of blanking to a plain steel plate of constant thickness, ends of the plain faller body are shaped as desired by pressing and combing pins are attached to thusly shaped faller body by plastic molding technique.

United States Patent Field of Search ..19/129 R; 29/527.1; 264/271 IsumiY Oct. 24, 1972 [54] METHOD FOR MANUFACTURING A [56] References CitedGILL FALLER OF A CONSTANT THICKNESS FALLER BODY TYPE UNITED STATESPATENTS [72] Inventor: Ichim lsumi A6406, 212a Gazav 2,409,565 10/1946l-loldsworth ..19/129 R Yamada Shimo Suita shi, Osaka, 2,901,778 9/1959Sauvage ..l9/l29R Ja an 3,125,801 3/1964 Fields ..29/527.l X p 3,532,07710/1970 Mann ..19/129 R [22] Filed: March 8, 1971 y PrimaryExaminer-John F. Campbell [211 A 122013 Assistant Examiner--Donald C.Reiley, Ill

Related li fi D t AttorneyRobert E. Burns and Emmanuel J. Lobato [63]Division Of SCI. NO. 4,218,.1311. 20, I A method for manufacturing agill faller of ,a constant [30] Foreign Application Priority Datathickness faller body type wherein a faller body is formed by anapplication of blanking to a plain steel Jan. 27 1969 Japan ..44/7345 1pl f constant thickness, ends of the plain faller body are shaped asdesired by pressing and combing I a-$1 ll! /5 1L. 9l1 9 RLHZ64/ZJHL pinsare attached to thusly shaped faller body by Int. Cl ..B23p 17/00, B23p25/00 plastic molding technique 4 Claims, 36 Drawing Figures PATENTEDB24 1912 SHEET 1 BF 5.

METHOD FOR MANUFACTURING A GILL FALLER OF A CONSTANT THICKNESS FALLERBODY TYPE The present application is a continuation-in-part typedivisional application of my copending US. patent application SerNo.4,218 titled GILL FALLER AND A METHOD FOR MANUFACTURING THE SAME andfiledon Jan. 20, 1970. i

The present invention relates to an improved method for manufacturing agill faller of a constant thickness faller body type, more particularlyrelates to a method for manufacturing agill faller of a constantthickness faller body type with omission of the conventionallyindispensable cutting operation for the purpose of shaping ends.

As is well-known, the typical conventional gill faller is provided withan intermediate portion for upholding combing pins and end portions forengagement with gill faller guide and drive mechanisms of the gill boxwhereon the gill fallers are used. Generally, the intermediate portionis provided with one or more elongated grooves wherein the combingpinbuttsareto be embedded so that the combing pins are disposed to thegill faller in a prescribed alignment or alignments. In somemodification, the combing pins are disposed firstly to a pin strip unitor units and the unit or units are fixedly inserted into the grooves ofthe gill faller intermediate portion. In any of the two cases, the gillfaller intermediate portion has to be provided with one or more of suchelongated grooves for the combing pins disposition. Further, shaping ofthe sideways end portions has been in general, carried out throughapplication of the known cutting operation.

The above-described conventional gill faller manufacturing method isinevitably accompanied with several fatal drawbacks such as mentionedbelow.

By the application of the cutting operation, the sideways end portionsare provided with portions of different thicknesses and, during theactual use of the gill faller, various stresses caused by externalmechanical attacks tend to concentrate upon boundaries between suchportions of different thicknesses. Such stress concentration expeditesaccidental breakage of the gill faller. Further, because the sidewaysend portions must be shaped by cutting, the end portions are required tohave a sufficient thickness for withstanding mechanical attacks exertedthereto during the cut shaping operation. This inevitably leads toundesirable increase in the resultant weight of the gill faller, whichincrease is not welcomed in the practical use of the gill faller becauseit possibly causes unsmooth movement of the gill faller on the gillingmachine. It should be noted further that a thick gill faller structurerequires unnecessarily in-. creased use of the material steel.

In addition to the above disadvantages, necessary formation of thegrooves in the intermediate portion requires a very precise work. It isknown that it is very difficult to form a groove through or to ahardmember such as a steel plate, which groove has horizontal sizesconsiderably small in comparison with its vertical sizes. Thisdifficulty is increased especially when precise work is required as inthe manufacturing of the gill fallers. In order to mitigate thisdifficulty, a use of low carbon steel has been proposed, but this isaccompanied with other demerits such as lowering in the fatiguestrength.

In view of the above-described drawbacks inevitably encountered in theconventional art, the present invention aims to provide a method formanufacturing a gill faller, which is free from troubles caused by thegroove(s) provision, with omission of the conventional cutting operationfor the sideways end parts shaping purpose.

In the inventional method, a faller body is firstly formed by anapplication of blanking, in a prescribed pattern, to a plain steel plateof constant thickness. Subsequent tothis blanking, pressing is appliedto the sideways end portions so as to provide them with desired shapes.Thusly prepared gill faller body is placed within a molding die togetherwith combing pins to be attached thereto in a prescribed alignment oralignments. After both are prescribedly mounted in the molding die, asuitable plasticmaterial is extruded into the molding die for thepurposed combination of the two. Various modifications are available foreffectuating theprescribed alignment or alignments of the combing pinsin relation to the already prepared gill faller body.

Furtherfeatures and advantages of the inventional method will be mademore apparent from the ensuing description, reference being made to theaccompanying drawings, wherein;

FIG. 1 is a front view of thegill faller body plain plate used in theinventional art, 4

FIGS. 2A and 2B are plan views of the gill faller body end portionsafter press shaping, a

FIG. 3 is a perspective part view of the gill faller made according tothe inventional method,

FIGS. 4A to 4D are transversal cross-sectional views of the gill fallersmade according to the inventional method, wherein a singlefaller body isused,

FIGS. SAto 5H are transversal cross-sectional views of the gill fallersmade according to the inventional method, wherein two faller bodies areused,

FIGS. 6Ato 6C are frontand transversal cross-sectional views of themetallic die used in the inventional method,

FIGS. 7A to 7C are front and transversal cross-sectional views of themetallic die used in combination with the one shown in FIGS. 6A to 6C,

FIGS. 8A to 8C are front and transversal cross-sectional views of theconsolidated metallic die with comb- FIG. 9B is a transversalcross-sectional view of the gill faller manufactured thereon,

FIG. 10A is a partly transversal cross-sectional view of another moldingdie usable in the inventional method and FIG. 10B is a transversalcross-sectional view of the gill faller manufactured thereon,

FIG. 11 is a front view of the provisional ribbon used in theinventional method,

FIG. 12 is a perspective view of a metal casing used in combination withthe ribbon shown in FIG. 11,

FIGS. 13A and 13B are cross-sectional views showing the formation of apin upholding die on the metal casing shown in FIG. 12,

FIG. 14 is a transversal cross-sectional view of the metal casing usedin the inventional method,

FIGS. A and 15B are transverse cross-sectional and partly-sectionalfront views of the pins upholding die with the combing pins beingmounted thereto.

In the inventional method for manufacturing a gill faller, a purposedpattern of a gill faller body plain plate such as shown in FIG. 1 isformed in the first plate through application of a blanking operation toa plain steel plate of a constant thickness. This gill faller body plainplate 1 consists of an intermediate portion 2 and a pair of end portions3 integral sideways of the intermediate portion 2. It will be understoodthat the intermediate portion is purposed for later dispositions of thecombing pins whereas the end portions 3 are purposed for engagement withthe known gill fallers guide and drive mechanisms.

Next,-the end portions 3 are subjected to suitable press shaping so asto provide them with necessary shapes adapted for engagement with theknown gill fallers guide and drive mechanisms of the gilling machines.Some typical shapes are illustrated in FIGS. 2A and 2B. In the exampleshown in FIG. 2A, the end portion 3 is composed of a portion 4 integralsideways of the intermediate portion 2 and adapted for engagement withfaller guides and ends of faller rails, a terminal portion 6 adapted forengagement with gill screws and a connecting portion 7 interveningbetween the portion 4 and the terminal portion 6. In the case of thegill faller having these type end portions 3, only one side of theportion 4, that is, downside of the portion in the drawing, iscooperative with the faller guides during the shifting cycle movement.Another typical example is shown in FIG. 2B, wherein the end portion 3is also composed of a portion 4, a terminal portion 6 and a connectingportion 7. In the case of this structure, both sides of the portion 4 iscooperative with the faller guides. In the case of this example, bothcomer parts 8 and 9 engage with the faller guides of the machine.

It should be greatly appreciated that no cutting operation is employedin the shaping process of the end portions 3. As is apparent from theforegoing discussion, because the cutting operation is not a need in theart of the present invention, the end portions are not required to havea sufficient thickness suitable for such shaping by the cuttingoperation naturally resulting in the thinner construction thereof.Reduction in the thickness naturally results in reduction in the gillfallers weight and a lightweight gill faller can be acquiredaccordingly. Elimination of the cutting operation is one of the mostimportant merits of the manufacturing method of the present invention.Thusly, troubles arising from heavy weight construction can be solved bythe employment of the method of the present invention. In addition tothis weight problem, elimination of the cutting operation has one moresignificant meaning. Elimination of the cutting operation makes itunnecessary to use low carbon steel as the gill .faller material andthis enables the gill faller of the present invention to be releasedfrom the problems relating to impact strength and fatigue strength.

After the gill faller body is thus prepared, combing pins must bedisposed to it in a prescribed alignment or, when required, alignments.

In general, in the disposition of the pins 11 to the faller body,combing pins are held by a jig in a prescribed arrangement. Next, thuslyheld combing pins are placed within a molding die together with the gillfaller body with their foot ends being in a predesigned positionalrelationship to the side surface of the gill faller body. By filling themolten plastic substance into the molding die, the pins are firmlycombined with the faller body after solidification of the plasticsubstance. In another embodiment of the method, a pair of gill fallerbodies are amalgamated together in a side by side superposedrelationship leaving a gap at least at a portion corresponding to theintermediate portions. Next, a plurality of combing pins are combinedwith one or more plastic strip units in a prescribed arrangement. Thuslyobtained pins holding plastic strip units are inserted into the gap andfixed therein by any of the known manners. Also in the pins disposition,formation of cavernous portions through or to the faller body iseliminated. As already explained, elimination of such operation releasesthe gill faller from any stress concentration problem, thickconstruction and the use of low carbon steel. Especially, elimination ofprecision work needed in such operation greatly contributes to thereduction of the gill fallers manufacturing cost.

Stable fixing of the pins in relation to the faller body can be easilycontrolled as desired through suitable selection of the used plasticsubstance in rotation to the molding condition.

One example of the gill faller thusly manufactured is shown in FIG. 3,wherein the combing pins 11 are firmly upheld by the intermediateportion 2 of the gill faller body with their butts (not seen in theillustration) being embedded within a plastic layer 13 at least partlycovering the intermediate portion 2.

Several types of combinations of the combing pins 1 1 with the gillfaller body intermediate portion 2 via the plastic layer 13 areillustrated in FIGS. 4A to 4D. As is seen in the illustrations, butts 12of the combing pins 11 are embedded firmly in the plastic layer 13,

The number of the gill faller bodies for a single gill faller can bemodified as desired and some of the examples are shown in FIGS. 5A to5H.

As for the above-mentioned plastic molding type disposition of thecombing pins to the gill faller body, various methods are employable,some typical embodiments being explained in detail in the ensuingdescription.

In the first embodiment, a pair of metallic dies 21a and 21b, such asshown in FIGS. 6A to 6C and 7A to 7C, respectively, are used. As shownin FIG. 6A, the metallic die 21a is provided, on its one surface to beassociated with the metallic die 21b, multiple vertical (in the drawing)grooves 23a of a semi-circular transversal cross section. The grooves23a are formed parallel to each other and, distances between theneighboring grooves are selected according to the particulars requiredfor the resultant gill faller. In communication with the bottom ends ofthe grooves 23a, a horizontal (in the drawing) groove 24a is formed asshown in FIGS. 6A and 6B. Near both sideway ends of the metallic die21a, a pair of stepped center holes 26a are 26a, a pair of recesses 27aare formed in the metallic die 21a body as shown in FIG. 6C.

On the other hand, the other metallic die 21b is also provided withvertical grooves 23b in an arrangement to conform to the verticalgrooves 23a of the metallic die 21a when both dies 21a and 211) areconsolidated together as later described. With dimension correspondingto that of the horizontal groove 24a of the metallic die 21a, horizontalprojection 24b is formed (see FIGS. 7A and 7B). Near both sideways ends,a threaded centerhole 26b and a pair of projections 27b are formed asshown in FIG. 7C. Dimensions of the above-described parts are selectedwith regard to the center holes 26a and recesses 27a of the metallic die21a.

Next, both metallic dies 21a and 21b are consolidated together as shownin FIGS. 8A to 8C, wherein the combing pins 11 are inserted intocircular holes 28, which are formed by the semi-circular grooves 23a and23b, with their butts being exposed outside of the consolidated metallicdie 21. In this consolidated condition, the projection 24b and 27b ofthe metallic die 21b are accepted within the horizontal groove 24a andthe recesses 27a of the metallic die 210, respectively. In order tofixedly consolidate the two dies 21a and 21b, a pair of set screws 29are threaded into the threaded center holes 26b through the steppedcenter hole 26a as shown in FIG. 8C.

Next, the consolidated metallic die 21 upholdingthe combing needles 11is placed within a separable type molding die 31 with the gill fallerbody 1 as shown in FIG. 9A. As is seen from the drawing illustration,the molding die 31 is internally provided with, in addition to a cavityfor accommodating the consolidated metallic die '21, an internal cavity32 embracing the faller body 1 and the combing pin butts and a conduit33 for communicating the internal cavity 32 with a plastic materialinlet 34. After the placing of the two members 1 and 21, suitableplasticmaterial is'introducedinto the internal cavity 32 via the inlet34 and the conduit 33. After adequate solidification, a gill fallerhaving a transversal cross section such as shown in FIG. 9B, which isthe same with that shown in FIG. 4A, is obtained. By adjusting therelative .positionof the faller body 1 and the combing pin butts withinthe internal cavity 32 various types of gill fallers such as shown inFIGS. 4B to 4D and A to 5H can be obtained. For example, when thearrangement is so designed as shown in FIG. A, a gill faller such asshown in FIG. 10B, which is the same with that shown in FIG. 5E, can beobtained.

Another embodiment of the plasticmolding in the inventional method willbe describedhereinafter. In the case of this embodiment, a pin dieupholding which in some sense corresponds to the consolidated metallicdie 21 used in the foregoing embodiment, is prepared in the first placeas follows.

A plurality of combing pins 11 are fixed at their butts to an elongatedmember 41 by, for example, soldering with prescribed interveningdistances so as to form a provisional ribbon 42, as shown in FIG. 11.Separately from this, a metal casing 43 having an internal cavity 44such as shown in FIG. 12 is prepared. Surrounding the upper opening ofthe internal cavity 44, a cover plate 46 is fixed to the metal casing 43by set screws 47. Next, the above-prepared provisional ribbon 42 ismounted on the metal casing 43 with the points of the resinous powder asshown in FIGS. 13A and 13B. After i the filled substance is solidified,the provisional ribbon 42 is removed therefrom and a pin upholding die49 having holes 51 receptive of the combing pins 1 l is obtained, whichdie is illustrated in FIG. 14. Next, the

combing pins 11 are inserted into the holes 51 with their butts beingexposed outside as shown in FIGS. 15A and 15B. Thusly prepared pinupholding die 49 and the gill faller body or bodies 1 are placed withinthe molding die 31 such as used in the preceding embodiment and afterextrusion of the plastic material, a gill faller is acquired in amannersimillarto that used in the preceding embodiment.

Although in the case of the foregoing embodiment, only a singleset ofconsolidated metallic dies 21 and its related parts or pin upholding die49 and its related parts are placed within the molding die 31, multiplesets of them can be placed within the molding die 31 for the plasticmolding purpose.

What is claimed is:

1. An improved method for manufacturing a gill faller of a constantthickness faller body type comprising,in combination, forming a plainfaller body plate of a prescribed pattern by an application of blankingto a plain steel plate of a constant thickness, subjecting sideway endportions of said plain faller body plate to a press shaping so as toform a gill faller body of a desired shape, placing thusly obtained gillfaller body within a molding die together with combing pins to beattached thereto in a prescribed alignment or alignments and ex trudinga suitable plastic material into said molding die for combination ofsaid gill fallerbody with said combing pins.

2. An improved method as' claimed in claim 1, wherein two sets of gillfaller bodies are placed within said molding die in a side by sidedisposition leaving at least a partial gap between the two and saidcombing pins are aligned with their butts inserted within said gap.

3. An improved method as claimed in claim 1, wherein after preparationof said gill faller body, a plurality of combing pins are upheld by aconsolidated metallic die with their butts being exposed outside andsaid consolidated metallic die upholding said combing pins is placedwithin a molding die together with said gill faller body.

4. An improved method as claimed in claim 1, wherein after preparationof said gill faller body, a plurality of combing pins are soldered attheir butts to an elongated member so as to form a provisional ribbon,said provisional ribbon is mounted on a metal casing with points of saidcombing pins directed towards a bottom of an internal cavity of saidmetal casing, said metal casing is filled with a metallic powdersolution containing resinous powder, said ribbon is removed from saidmetal casing after solidification of said metallic powder solution,combing pins are inserted into holes formed in said solidified metallicpowder solution v r 7 in the preceding operation, thusly formed pinupholding die is placed within said molding die together with said gillfaller.

1. An improved method for manufacturing a gill faller of a constantthickness faller body type comprising, in combination, forming a plainfaller body plate of a prescribed pattern by an application of blankingto a plain steel plate of a constant thickness, subjecting sideway endportions of said plain faller body plate to a press shaping so as toform a gill faller body of a desired shape, placing thusly obtained gillfaller body within a molding die together with combing pins to beattached thereto in a prescribed alignment or alignments and extruding asuitable plastic material into said molding die for combination of saidgill faller body with said combing pins.
 2. An improved method asclaimed in claim 1, wherein two sets of gill faller bodies are placedwithin Said molding die in a side by side disposition leaving at least apartial gap between the two and said combing pins are aligned with theirbutts inserted within said gap.
 3. An improved method as claimed inclaim 1, wherein after preparation of said gill faller body, a pluralityof combing pins are upheld by a consolidated metallic die with theirbutts being exposed outside and said consolidated metallic die upholdingsaid combing pins is placed within a molding die together with said gillfaller body.
 4. An improved method as claimed in claim 1, wherein afterpreparation of said gill faller body, a plurality of combing pins aresoldered at their butts to an elongated member so as to form aprovisional ribbon, said provisional ribbon is mounted on a metal casingwith points of said combing pins directed towards a bottom of aninternal cavity of said metal casing, said metal casing is filled with ametallic powder solution containing resinous powder, said ribbon isremoved from said metal casing after solidification of said metallicpowder solution, combing pins are inserted into holes formed in saidsolidified metallic powder solution in the preceding operation, thuslyformed pin upholding die is placed within said molding die together withsaid gill faller.